Drexler Differential

[Morgan Percy]

We have recently purchased a Drexler FSAE Diff Version 1. Does anyone know of a off-the shelf yoke that works? From what I have heard so far is that most teams make their own yoke with splines to fit the differential. As we have a tight budget this is not really an option for us. Any help would be appreciated.

[PatClarke]

Please, please forgive me, but I really do have to do it again =]

http://nanoengineer-1.com/cont...om_content&task=view (http://nanoengineer-1.com/content/index.php?id=44&option=com_content&task=view)

Pat

[Simon Dingle]

Hi,

Which year of diff have you bought and where from?

What do you mean by a "yoke"? Are you planning on running universal joints on your driveshafts?

[Morgan Percy]

It is the 2008/2009 Revision 1 model straight from Drexler and yes we would be looking at universal joints/hook joints.

[Perito]

Hello:

I'm waiting too for my first Drexler (past years we run with a Bacci lsd, but it is a little bit heavy), and we are planning to realize the differential output shafts with flanges that fits with the halfshaft CV joints. I think this is the common procedure for who use a drexler differential.

Moreover, IMHO, a pair of hooke joints is not the better solution for the halfshafts. A cheap way could be the use of some aftermarket CV joints (or tripod joints). Past years we used the VW polo cv joints and we don't had problem with it (apart for the weight...).

This is my opinion, correct me if something is wrong!

[smb96]

Hi,

in the case you mean the shaft which connect the diff with the joints, you have to manufacture them by your self.
You just purchased a diff for ca. 1500€ and now you are too tight on budget to build 2 small shafts?

Thomas
Rennteam Uni Stuttgart

[Morgan Percy]

Hello

Yes I mean the short shaft that is usually attached to the CV joint or universal/hooks joint.

Not all teams have large budgets to spend and yes we are tight on budget so we are looking at as many options as possible.

We have talked with Drexler and they do not know of any manufactured items with the same spline dimensions. Just thought there might be a chance that a team had found something that does fit. Probably will just design one and have it manufactured.

[Simon Dingle]

Hi Morgan,

We've just purchased a Drexler too (although it's the 2010) and are going for a similar arrangement as Perito.

If Drexler don't know of any off-the-shelf joints that fit, then I would be surprised if there were any. However, you could try giving the spline information to a specialist (e.g. GKN Driveline) and seeing if they already do anything that fits. I think you'd be pretty lucky though.

Simon

[TorqueWrench]

Not to sound mean or anything but if you are short enough on money that you cannot afford materials to make 2 shafts, why did you go with such an expensive differential? It just seems a shame for some very heavy u-joints to be attached to that nice of a unit.

You can probably make said shafts in house for the cost of material. Splines can be cut in house using a mill if you are careful.

[Morgan Percy]

The Drexler was chosen because of the bearing arrangement simplified mounting and reduced weight. Was seen as more as an investment that would be used for multiple years and worth the money. Everything would normally be made in house but due to political issues we have been forced to have everything machined by an outside company which severely cuts into our budget. It was not known that we were going to have such a hard time getting anything made when the diff was purchased. The uni bought late last year two brand new lathes, two mills, a large 5-axis milling machine and autoclave on top of a 4-axis CNC mill and CNC Lathe that was kept from before, but can't get anything made. Ridiculous.

[TorqueWrench]

Ouch, that changes alot of things. Before you lock yourself into using u-joints, try calling all the local machine shops in your area. I was quite surprised at how willing most places are to make parts for a car in exchange for a logo on the car.

[jaca]

Originally posted by PatClarke:
Please, please forgive me, but I really do have to do it again =]

http://nanoengineer-1.com/cont...om_content&task=view (http://nanoengineer-1.com/content/index.php?id=44&option=com_content&task=view)

Pat

ha! that might have some issues handling all the torque..

[kcapitano]

https://www.rcvperformance.com...re/catalog/index.php (https://www.rcvperformance.com/store/catalog/index.php)
you can buy the Formula SAE tripod axle kit and they will fit it to your drexler. Its a little expensive at $850 USD, but its the easiest solution you will find.

[Umur Selek]

Call up Taylor Race and see if they can get you "blank" shafts that you can send out to get splined ($55 each from moser)

[mevdog]

sorry to dig this old thread up but did you find a suitable off the shelf solution?
thanks in advance

[AndreasK]

Hi mevdog,

I'm currently working on the same part and I found this at Taylor-Race.com:
http://www.taylor-race.com/part.cfm?id=4708

For me there's the question how to fix the stub in the diff to restrict longitudinal movement. Perhaps someone has a hint for me?

Andreas

[Kirk Feldkamp]

You mean *lateral* movement? http://fsae.com/groupee_common/emoticons/icon_wink.gif Unless I'm mistaken, the Torsen uses wire spring sorta-circlips that sit on the end of the cut stubs. Basically, they compress very slightly on the way in, and then expand out once they get past the spline in the diff. I say "very slightly" because you still have to be able to knock them back out. The reality is you shouldn't have a lot of thrust (axial load) in that area considering that's the joint with the plunge in it. The axial component of the forces generated by an angled axle should be relatively small, plus you should have a spring plunger in the end of the axle itself to keep it centered. I would think the plunger would help push back at the inboard stub if it was trying to work its way out.

-Kirk

[Kirk Feldkamp]

*WRONG!* I went downstairs and looked at the one in my garage, and it doesn't appear the Torsen uses any clips to hold the stubs in place. In the setup I have, a bearing was mounted to the stub via a cup, and that cup mounted onto the diff carrier. Basically, the press fit of the bearing onto the stub shaft is holding it axially.

-Kirk

[AndreasK]

Hi Kirk,

I think i've seen this kind of approach. I'll see if that can be integrated in our housing. Thanks for your explanation.

I ment longitudinal in relation to the stubs. But yes, lateral in relation to the vehicle ;-)

[kcapitano]

My team has used Torsen differentials in the past with just the press fit of the bearing holding the stub-shafts in place. They all came loose. We never had a stub pull so far out that it disengaged from the spline in the diff, but they all wobbled significantly and you could pull them in and out with your hands.

In my last year we cut part of the spline on the diff gears away so we could put snap grooves onto the end of the stubs. It didn't turn out because I didn't spec the right snap rings, but it could work if you do it right.

Of course, if you're using the Drexler it has plugs you can bolt the stub into.

[AndreasK]

Hi kcapitano,

and how would you be able to assemble or disassemble this solution?

As far as i can see in this drawing (http://www.torsen.com/files/University%20Special%20012000.pdf) theres almost no room between the diff gears to fit a snap ring on the stubs. Not to mention the disassembling.

[kcapitano]

Andreas

You're right, there is no room between the side gears to fit a snap ring on the stubs. We machined away part of the spline on the inboard side of the side gears. If you looked at a cross section, like section A-A in the link you posted, it would look like the snap ring was sitting inside the side gear.

In regards to assembly/disassembly, that's up to you to figure out. It will work with the stock housing Torsen sells, but you can make it a bit easier if you make your own differential housing. We made our own housing and had no trouble. Just think about the sequence of operations you need to go through when assembling the whole thing.

[AndreasK]

hmpf, jeah. Now i get it http://fsae.com/groupee_common/emoticons/icon_wink.gif